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ABB Reliability Fingerprint

Consulting services for all industries. ABB Reliability Fingerprint. Identifies opportunities for productivity, reliability and cost improvement. If only it were this simple…. I found the problem. The batteries are upside down. Introduction.

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ABB Reliability Fingerprint

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  1. Consulting services for all industries ABB Reliability Fingerprint Identifies opportunities for productivity, reliability and cost improvement

  2. If only it were this simple… I found the problem. The batteries are upside down.

  3. Introduction • Plant automation provides abundant and valuable process, production and equipment data • The ABB Reliability Fingerprint collects and evaluates site data to identify opportunities for productivity, reliability and cost improvement • Collected data is used to benchmark your site against leading process industry and manufacturing sites • Areas of opportunity are identified and evaluated by ABB process and industry experts • Recommendations for sustainable productivity, reliability and cost improvements are provided

  4. Benefits • Develops snapshot of current practices • Benchmarks site against industry best practices • Establishes recommendations for site performance improvement • Identifies both short and long term benefits • Quantifies potential benefits • Productivity improvement (OEE) • Cost optimization • Reliability • Develops a strategy that will deliver benefits • Qualifies and quantifies opportunities

  5. Three-part assessment • Overall Equipment Effectiveness (OEE) • Composite measure of equipment availability, production rate and quality • Maintenance Performance • Evaluates maintenance practices: Utilization, Methodology, Performance • Reliability Culture • Evaluates roles and responsibilities, reliability training, failure analysis • Reliability-centered maintenance (RCM) • Root cause analysis (RCA)

  6. Description • Periodic assessment • Price based on number of Full-time Maintenance Employees (FTEs) • $15,000: <50 FTEs • $20,000: 50-100 maintenance FTEs • $25,000: 100+ maintenance FTEs • Performed by Reliability Service team • 2-Week program (week 1: data gathering, week 2: analysis and reporting off-site) • 1-2 consultants per week • Deliverable • Qualitative assessment of plant reliability and improvement plan • Quantitative assessment of financial business opportunities

  7. Paper Machine (PM) example From the base data provided: • PM1 loss est. at 1,163 tons 10% improvement Year 1 = $34,890(10% x 1,163 x $300) • PM2's loss est. at 2,497 tons 10% improvementYear 1 = $74,910(10%x 2,497 x $300) Total for both machines Year 1 = $109,800 During Year 2:Additional10% PM1 increase = $31,401 PM2 = $67,419 Total for both machines Year 2 = $98,820 Each extra or marginal ton of PM1 availability = $300 ($756/hour)

  8. 1. OEE assessment Evaluates process and assets • Applies proven analysis methodology • Measures relationships • Equipment availability • Production efficiency • Rate of quality • Uncovers potential benefits Maintenance Mgr. Production Mgr. Quality Mgr. Financial Mgr. Equipment Availability (A) Production Rate (P) QualityFactor (Q) Product People Material HR Manager Supply Manager Profit Plant VP/Manager

  9. 2. Maintenance Performance Assessment Includes maintenance cost Financial Mgr. Maintenance Mgr. Production Mgr. Quality Mgr. Product People Material HR Manager Supply Manager Profit Plant VP/Manager • Utilization • Time spent waiting • Craft coordination • Availability of drawings • Craft flexibility • Parts availability • Level of rework • Methodology • Business processes • Planning • Special tools • Scheduling • Standard jobs library • Rebuild procedures • Performance • Skills • Training • Job interruptions • Supervision • Morale • Labor issues • Precision maintenance

  10. 3. Reliability Culture Assessment: Roles and responsibilities, reliability training, failure analysis • Review maintenance practices and maintenance culture (planning and scheduling effectiveness) • Understand plant reliability culture • Identify perceived strengths and improvement opportunities Review organizational structure (job responsibilities, ratios) Identify maintenance and reliability gaps Financial Mgr. Maintenance Mgr. Production Mgr. Quality Mgr. Product People Material HR Manager Supply Manager Profit Plant VP/Manager

  11. Primary Activities Information Gathering (On- and off-site) Analysis (off-site) Delivery (on-site) • 1 Week on-site • Pre-arrival data collection packet • Collect Data on-site • Validate Data • Confirm information understanding with Customer • 1 Week off-site • Develop Metric Charts • Draw Cost/Structure Conclusions from Metrics • Finalize OEE Calculations • Develop OEE Waterfall • Develop Business Case with ABB Account Personnel • Develop Findings Presentation • Complete Executive Summary • Present Reports

  12. Assessment Evaluation • The assessment findings are reviewed by a collaborative Reliability/ABB Field Services Team • The team maps service portfolio opportunities to identified performance gaps

  13. OEE Overview Total Available Production Time Planning Factor (Pf) Non- production time Planned production time Availability Factor (A) Gross operating time Availability Losses Equipment failure Set-up and adjustments Performance Factor (P) Net operating time Speed Losses Idling and minor stoppages Reduced speed Quality Factor (Q) Valuable operating time Quality Losses Defects in process Start-up losses OEE% Availability factor(A) Performance factor(P) Quality factor(Q) Valuable operating time = X X = Planned production time

  14. Sample DeliverableOEE Waterfall – PM 1: OEE = 75% PM 1: OEE = 75 % 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 Total Time (hours) (8760 hrs) Steam (2 hrs) Electrical (98.1 hrs) Other (5.1 hrs) Planned Production Time (8654.8 hrs) Scheduled Total Outages (294 hrs) Electrical (120.9 hrs) Mechanical (191.4 hrs) Roll Failures (59 hrs) Instrumentation (6.9 hrs) DCS (15.2 hrs) Hydraulics (4.1 hrs) Drives (13.7 hrs) Operations (332.4 hrs) Breaks (410 hrs) Available Time (7207.2 hrs) Quality Losses (730 hrs) Making Good Product at MPR (6477.2 hrs)

  15. Maintenance Performance Example: Maintenance Cost is tied to: • Effectiveness of maintenance • Skill level and quality of knowledge of personnel • Asset type • % of unplanned maintenance • % of predictive maintenance Example PM#1 - Vibration detects bearing wear • Proactive Maintenance - Bearing is changed (cost $5,000) • Reactive Maintenance - Bearing is not changed, Machine fails (cost $100,000) 20 World class 1.5% – 2.0% 14 Your facility 12 10 Maintenance cost as % of facility replacement cost 8 6 4 2 0 5 10 15 20 25 30 35 40 45 Facility number

  16. Areas evaluated with fingerprint Reliability Culture Areas High dB Avg Site Score Low Performance Assurance Continuing Education Management Leadership Preventive & Predictive Maint. Roles and Responsibilities Responsive Maintenance Organizational Structure Supplier & Services - Stores Physical Assets Program

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